Power source
Component Fault symptom Cause
Primary cable No or low welding output Bad or incorrect primary
connection, lost phase
Earth cable and clamp Arc will not initiate Damaged, loose or undersized
cables and clamps
Connectors and lugs Overheating of connectors
and lugs
Loose or badly crimped
connectors
Switches Erratic or no output control Switches damaged or incorrectly
set for the application
Wire feeder
Component Fault symptom Cause
Gas solenoid valve No gas flow or gas flows
continuously
Gas valve faulty or sticking in open
position
Wire feed rolls Wire slippage, wire deformation Incorrect feed roll size, incorrect
tension adjustment, misalignment
Inlet, outlet guides Wire shaving or snarling Incorrect wire guide sizes,
misalignment
Universal adaptor Wire restriction, gas leaks, no
trigger control
Universal adaptor not correctly
mounted or secured, incorrect size
of internal guide, bent contact pins
Wire feed speed control No control over wire feed speed,
no amperage control
Faulty wire speed feed
potentiometer, wire feed motor in
overload or trip condition
Wire inch switch Wire live when feeding through
cable and gun before welding
Faulty wire inch switch,
inappropriate use of gun trigger
switch
Spindle Wire spool drags or overruns Spindle brake set too tight or too
loose, spool not properly located
on spindle
5.0 Troubleshooting and Fault Finding
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